Yamaha ET340D Manual

•

YAMAHA

SNOWMOBILE

[Frame serial number: 8J6-025101

8J6-039999 ]

Engine serial number: E338-025101

E338-039999

LIT

-12618-00-24

8J6-28197-10

CONTENTS

NEW

SERVICE PROCEDURE ..............................................................

....

MAINTENANCE

INTERVALS

....

......

....

..................................

....

............. 2

3. SPECiFiCATIONS.

...

.....

....

.......

...

.....................................

....

.....

....

4. SPECIAL TOOLS.......................

............

.....

...

............

...

............................. 9

WIRING

DIAGRAM

............................................

....

..........................

6. WIRE

AND

PIPE

ROUTING

DIAGRAM

......

..................

......................

NEW

SERVICE

PROCEDURE

(New

service procedure applied

the

1980

ET340D)

CARBURETOR

To achieve

the

precise

fitting

the

main nozzl

the

main nozzle is press-

fitted

the

mixing

chamber body, and

accordingly the main nozzle

cannot

removed.

1980

ET340D

2. For better performance, the recom-

mended

type

the main

jet

which

more effective at alititudes is changed.

[Main

jet

setting

chart]

-3

0°C -

°C -

10°C

ooe

°C

Altitude

(-22

(-4

(14

(32°

(50

(68°

I I I I I I

#220

#240

Sea

level

(Std) .

250

#220

600m

(2000

ft)

#240

(Std)

220

1200m

(4000

ft)

-#24

210

#210

1800m

(6000

ft) *

#200_

#200

2400m

(8000

ft)

#210

--#190

3000m

(10000

ft)

f--

#190

or more

#200

Newly

changed specification.

-1

1980 ET340D

MAINTENANCE

INTERVALS

[PERIODIC

MAINTENANCE]

Every

Check point

hrs. or

hrs or When Seasonally

400

800km

1600

km necessary

(250

mil

(500mi)

(1000mi)

ENGINE:

Tightness

bolts and nuts a a

Bends. cracks and

wear

a a

Abnormal noise a a

Loose connection and breaks

fuel and pulse pipes a a

Loose connection and breaks

oil pipes a a

Loose connection and breaks

oil delivery pipe a a

Manual rope starter system a a

Carburetor

•Operation

starter jet a a

•

Mixing

adjuster (pilot screw) a a

•Idling speed adjustment a a

Operation and adjustment

oil

pump

a a

Ignition

timing

Cylinder compressions a a

Cylinder head/exhaust pipe decarbonize a

Spark plug condition. gap and cleaning a a

Tightening

the cylinder

head**

DRIVE:

Tightness

bolts and nuts a a

Wear on slide runners a a

Primary drive system a a

V-belt a a

Secondary drive system a a

Sheave distance a a

Sheave offset a a

Brake pad

wear

a a

Brake operation and adjustment a a

Guide wheel rubber a a

Wear

drive track wheel sprocket a a

Drive track adjustment a a

Breaks in drive track a a

Bends in front and rear axles a a

Checking

lock washers a a

Drive chain

adjustment

a a

Drive chain oil level a a

BODY:

Tightness

bolts and nuts a a

Bends and cracks a a

Welded riveted.

joints

a a

Ski adjustment a a )

Ski runner

wear

a a

Breaks in fuel tank a a

Cleaning

fuel tank a

Fuel filter a

Loose connection and breaks in fuel pipe a a

Breaks in oil tank a a

Oil filter a

-2

1980 ET340D

Every

Check

point

hrs.

hrs

When

Seasonally

400

800

1600

necessary

(250

mil

(500mi)

(1000mi)

ELECTRICAL:

Wear. breakage

wire

covering 0 0

Breaks in high-tension cord 0 0

Voltage

egulato

working

voltage 0

Operation

engine

stop

switch

0 0

Operation

tether

switch

0 0

Headlight

0 0

Taillight 0 0

Brake

light

0 0

••

Retighten

every

hours

from the first use.

[LUBRICATION

INTERVALS]

Every

Lubrication

point

hrs. or

hrs

When

Seasonally

Grease

400

800

1600

km necessary Brand name

mil

(

500mi)

(1000

mil

ENGINE:

Starter

case 0

Oil

pump

control box 0 0 Aeroshell grease #7A

Esso Beac

325

grease

Pump

drive cover 0 0

Oil in the oil tank 0 YAM.A.LUBE 2-cycle oil

DRIVE:

Primary sheave

weight

0 0

Molybdenum

disulfide

and roller

pins

snowmobile

grease

Secondar

shaft

and 0 0

Molybdenum

disulfide

sliding sheave

snowmobi

le grease

Front axle

housing

0 0

Shaft

1 and

shaft

2 0

(Slide rail) 0 Light all-purpose grease

Drive chain oil Gear oil API

"GL

-3"

replacement

0 0 SAE #

#BO

BODY:

Steering

column

lower

0 0

Light

all-purpose grease

bearing

Steering

column

per

0 0

Motor

oil

bearing

Steering links 0 0

Ski

column

0 0

Ski

wear

plate

0 Light

all-purpose

grease

Ski retaining

0 0

8rake

wire

end

stopper

0 0 Esso Beacon

325

grease

and brake lever

- 3 -

1980

T340D

SPECIFICATIONS

NOT

.....

New

specification

General (Compared

with

1979

ET340C)

Model

ET340D

Model

(I.B.M. No.) *

ET340D

(8J6)

Frame I.D. &

starting

number

8J6-025101

Engine I.D. &

starting

number

E338-0251

Dimension:

Overall length * 2,

555

(100

.6 in)

Overall

width

(std)

970

(38.2

in)

Overall height

(w/wind

shield)

1,040

(40.9

in)

Engine

Descripti0

Engine type

n cooled

two

-stroke 5-

port

twin

cylinders

Engine

model

E338

Displacement

338

cc (

.6 cu.in)

Bore X Stroke

.36

2.35

in)

Effective compression ratio

6.5:

tarting

system Recoil hand starter

Ignition

sys

tem

.D.1.

Lubrication system

"Autolube"

oil

inspection

Cylinder hea

Combustion

chamber

volume

(with

spark plug) 2

3 cc (1.

cu.in)

Compress

ion

chamber

type

Dome

+ Squish

Head gasket

thickne

0.5

(0.

in)

Cylinder:

Material

Cast

iron

sleeves a

minum

Bore size

.36

2 in)

Taper

limit

0.05

(0.

0020

in)

Out

round

limit

0.01

.0004

in)

Piston:

Piston sk

irt

clearance

(Measuring

point)

040

0.045

(0.001 6

0.0018

in)

(10

from

piston

kirt

end)

ton

oversize 1st

60.25

(

2.372

in)

2nd

60.50

.38

2 in)

3rd

(

2.392

in)

4th

61.00

(2.

402

in)

pin outside

diameter

X length

¢16

(¢0.6

X 1.85 in)

Piston ring:

Piston ring design (Top) Keys

ton

ring design (

2nd

) Keystone

Ring end gap (installed) (Top)

0.35~

0.55

014~

0.022

in)

Ring end gap (installed) (2nd) 0.

(0.014

0.022

in)

Small end bearing:

Type Needle b

ring

Big end bearing:

Type Needle b

ring

Crankshaft:

Crankshaft asse

mbly

width

(A)

160

±0.1

(6.30

0.004

in)

-4

1980

400

Crankshaft

assemb

width

(F)

g05

(204

g002

in)

Cranksha

deflection

(0)

0.03

-1)

0.04

(0-2)

0.04

-3)

0.03

(0-4)

Con

necting

rod large end side clearance

(C)

25~0

(0.01

0~O.014

in)

Connecting

rod small

end

deflec

tion

(P)

2.0

(0.

079

in)

---P

Q 0 -4

.:J

l U

Crank

outside

diameter

length

rjJ

(rjJ0866 X

2008

in)

Crank pin

type

lid shaft assembly

type

with

serration

Cra

bearing

type

t) X q'

#6306

special 1 pc.

Crank bearing

type

(Center) X

q'ty

6206

special X 2 pcs.

Crank be

aring

type

(Right) X

q'ty

6305

special X 1 pc.

Crank oil seal

type

(Left) X

q'ty

FPJ

2TS

X 1 pc.

Crank oil seal type (

er) X

q'ty

byrinth

seal X 1 pc.

Crank oil seal

type

(Right) X

q'ty

FPJ

-25

S X 1 pc.

Carburetor

Type &

manufacturer

quant

ity

838-34

MIKUNI

X 1 pc.

D. Mark

8J600

Main

jet

(MJ.)

240

lot

jet

(PJ)

Pilot

screw

(P.

1.0

turns

out

Throttle

lve

(ThV)

Valve seat

(V.

)

rjJl

(0.

059

in)

oat

height

± 1

(

0.98

0.04

in)

dling

engine

speed

1700

min

Main

jet

sett

ing

chart

°C -

°C O°C

°C

° F) (- 4 °

(

°F) (32° F)

(50

°F) (68°

Altitude

I I I L I

240

Sea level (Std)

- #2

220

600m

000

It)

240

(Std)

220

1200m

(

4000

It)

r----#

210

1800m

(6000

It)

•

_#2.

220

200

2400m

(

8000

It) #

210

- #

190

3000m

(1000

It)

#190

or more #

200

•

New

ly changed specificati

- 5 -

1980

ET340D

Lubrication:

Autolube

pump

Color

code

Autolube

pump

Minimum

stroke

Autolube

pump

Maximum

stroke

Autolube

pump

-Reduction ratio

Autolube

pump

Output

Min./200

strokes

Autolube

pump

Output

Max./200

strokes

Autolube

pump

wire

free

play

Oil

tank

capacity

Oil grade

Drive and track suspension

Transmission:

Type

Drive

ratio

Engagement

rpm

Primary spring:

Part No.

Color code

Secondary

spring:

Part No.

Col

code

Secondary spring pre-load

(twist)

Sheave distance

Sheave

off-set

V-belt

width

and

outer

line

length

V-belt

wear

limit

Track suspension:

Type

Damper

type

Spring

color

code (Front)

Spring

color

code (Rear)

Slide runner

wear

limit

Track

width

Trade

deflection

Length on

ground

Wheel sprocket material and

number

teeth

Stopper

band

length

Secondary

drive:

Type

Reduction

ratio

Chain

pitch

Number

link

Free play

Chain

housing

oil

quantity

Chain

housing

oil grade

Brake:

Type

Brake pad thickness

Brake pad

wear

limit

Gap

between

pad and disc

White

0.20

0.25

(0.0079

0.0098

in)

1.67

1.87

(0.0657

0.0736

in)

1/32

0.50

0.63

(0.0169

0.0213

oz)

4.1 5

cc (0

1403

0.1589

oz)

± 1

(0.98

0.04

in) at idle

2.4

Liter (2.5 US.qt)

YAMALUBE

2-cycle

V-belt

automatic

centrifugal

engagement

3.5:

1 : 1

3000

r/min

90501-50500

Red

90508-40080

painted

160

266

±2

(10.47

0.08

in)

±1

(0.43

0.04

in)

31.6

1.099

43.3

in)

Slide rail suspension

Oil and gas

damper

Red

painted

(0.

394

in)

380

(15

in)

mm/l

0 kg (0.

1.18

in/22

Ib)

760

(29.9

in)

* Polyethylene

186.5

(7.34

in) (1st hole

from

the

bottom)

Chain

(#40K-2)

692)

12.7

(0.5 in) X

60L

+5 +

- 2

(0.4

0.08

In)

400

(13.5

oz)

Gear oil API

"GL3"

(SAE

#75

85)

Disc brake

7.3

(0.

287

in)

1.0

(0.04

in)

0.2

1.0

(0.008

0.039

in)

-6-

1980

ET340D

Chassis

Frame:

Material

Aluminum

+ Steel

Steering system:

Caster (ski

column)

Camber 0°

Ski length X

width

X thickness

980

120

1.6

(38.6

4.7

0.06

Ski stance

850

(33.5

in)

Ski

toe

out

0.23

mm)

Steering linkage type Tie-rod

Lock

lock angle (Ski) Right ski.

27.6

24.8

Left ski.

24.8

27.6

Lock

lock angle (Steering

column)

Right:

54.3

Left:

56.3

Front

suspension:

Type Leaf spring

Damper

type Oil

damper

Fuel tank:

Capacity

22.7

liter (6 US. gal)

Fuel grade Regular gasoline

Electrical

Ignition

system:

Type-

flywheel

magneto

(C.D.1.

Type)

Model/manufacturer

F3T352/MITSUBISHI

Voltage

12V

Pulser coil resistance

9.00

°C

(68

(White/Red-Black)

Charging coil resistance

3500

°C

(68

(Brown-Black)

Charging coil resistance

15.00

°C

(68

(Blue-Black)

Ignition

timing:

B.T.D.C. 1.6 ± 0.1

(0.06

0.004

in)

Ignition

coil:

odel/M

ufacturer

CM62

ITACHI

Spark gap 9

(0.4

in)/

300

min

(0.6

in)/3,000

min

Primary

winding

resistance

0.150

°C

(68°F)

Secondary

winding

resis

tance

3.6kO at

°C

(68

Diode

(Yes

No)

Spark plug:

Type &

quantity

NGKBR-9ESx2pcs.

Spark plug gap *

7~0.8

(0.028~0.031

in)

Spark plug cap:

Type Rubber type

with

noise suppressor

Noise suppres

sor

resistance 5kQ

°C

(68

C.D.1.

unit:

Model/Manufacturer

8H4-20

MITSUBISHI

Lighting

system:

12V

l00W

Lighting

output

Lighting

coil resistance

0.190

°C

(68

(Yellow

-Bla

cK)

Head

light

type Semi shield \

Bulb

wattage/q'ty

12V-60/60W

X 1 pc.

Tail/brake

light

wattage

12V-8W/23W

A.C. regulator:

Model/Manufacturer

-2

4B/H

ITACHI

8B51 6B/

81 'BA

Voltage

.8 ±

0.5V

-7-

1980

ET340D

Tightening torque

Part

tightened

Thread size

Tighten

ing

torque

Remarks

Engine:

Spark

plug

M14

P1.25

2.8

m-kg

(

-Ibl

Cylinder head

P1.25

2.5

m-kg

ft-Ib

Flywheel

magneto

M1 6 P1.0

7.3

m-kg

(53

ft-Ib

Crankcase

upper

and lo

wer

P1.25

rst:

1.0

m-kg (

7.5

ft-Ibl

Final: 2.0

m-kg

-Ibl

Tightening

sequence

rr-

~t-

f--

$ 5

1$$

4 8$

tarter

pulley

P1.25

1.6

m-kg (11.5

ft-

Crankcase and E

ngine

bracket

M10

P1.25

3.0

m-kg

1.5

-Ib)

Drive and

track

su~penslOn

imary

sliding sheave and Cap

P1.0

11m

-kg (8 ft-Ibl

Installation

primary

sheave UNF1/ 2" Initial Use

Motor

m-kg

(

ft-Ib)

Loosen once and

retighten

6.0

m-kg

(

435

ft-Ibl

nstallation

drive chain

sprocket

M1 2

(

ft-Ibl

Use

cotte

r pin

Installation

dnven

chain

sprocket

M10

3.5

m-kg

(

-Ib)

Chain housing and Frame

.25

2.5

(

ft-Ibl

Chain

housing

cap

P1.

1.6 m-kg (

.5 ft-Ib)

Chain

tensioner

lock

nut

M10

.25 3.3

m-kg

(

ft-Ibl

stallation

front

axle R

M20

.0 9.0

m-kg

(

ft-Ibl

Front axle

housing

and Frame M8

P125

2.5

m-kg

8 ft-Ibl

Wheel

sprocket

and

ont

axle

0.5

m-kg

(

ft-Ibi

aft

1 and

Fra

M10

P1.25

5.5

m-kg

(

ft-Ib) Use LOCK-TI

haft

2 and Rear

bracket

M10

5.5

m-kg

(

ft-Ibl Use LOCK-TITE

Rear

bracket

and

Fra

P1.25

2.5 m-kg

8 ft-Ibl Use LOCK-TITE

Bracket 2 and Frame sliding 1

P1.0 1.2 m-kg (9

-Ib)

Installation

suspension

wheel

1.1

(8 ft-Ibl

Installation

rear guide

wheel

P1.25

2.5 m-

(18

ft-Ibl Use LOCK-

Installation

runner sliding 1 M6 P1.0 0.

m-kg (2

ft-Ibl

Use LOCK-TITE

Installation

runner

sliding

.0 0.6 m-

-Ibl Use LOCK-TITE

ivot

arm

1 and Bracket 2

5.0

m-kg (

ft-Ib) Use LOCK-TITE

Pivot 5 & 6 and Frame

sliding

.0 1.3 m-kg (9 5 ft-Ib) Use LOCK-

Frame sliding 1 and 2 & 3

2.5

m-kg

(18

-Ibl

Installation

stopper

0.35

m-kg

(2 5 ft-Ibl

Chassis.

Engine

mounting

bolt

M10

3.0 m-

(

ft-Ib

Ski runner

P1.25

1.4

m-kg

(10

ft-Ibl Use plain

washer

and

LOCK-TITE

- 8 -

1980 ET340D

eering co

lum

n and

Gate

2.0 m-kg (

-Ib) 1 Use lock

washer

eering

relay rod

adjusting

nut

M10

2.5 m-kg (

-Ib\ i

Out

side

arm

and

Ski co

lumn

M10

3.0 m-kg (

-I

b) I Use

lock

washer

and

wave

washer

Steerrng lo

wer

bracket

.2 5 2.0 m-kg (

.5 ft-Ib) Use

lock

washer

and

CK-TI

Installati

steering

column

1. 2

1.45

m-kg (

105

ft-Ib) Use lock

washer

tee

ring relay

ass'y

M10

3.0

m-kg

(

-Ib) Use co

tter

Universal

jOint

M10

2.5 m-kg (

ft-Ib

)

Ste

gate

1.4

m-kg

(

-Ib)

SPEC

IAL

TOOLS

1. 4-a.

10.

No. Description Tool No.

1 Di

gauge

90890-03097

2 Dial gauge stand No.2

90890-01195

3 Dial gauge needle

(56

mm)

90890

03098

4-a Flywheel puller

bolt

90890

01803

4-b Flywheel puller

attachment

90890

01804

4-c Flywheel puller

screw

90890

-01806

4-d Drive handle

90890

-01 81 7

4-e Flywheel puller

body

0890-01848

5 Rotor holding

tool

90890

-0

6 Primary fixed sheave puller

90890-01859

7 Sheave sub-assembly tool

90890

01858

8 Bushing

tool

90890-01877

9 Sheave gauge

90890

01875

Main

switch

ring

nut

tool

90890-0185

Pocket

tester

90890-03

Electro tes

ter

90890

03021

A.C. Regulator checker

90890-03090

- 9 -

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